Modular safety valve system, valve module and method of setting parameters of a valve system

ABSTRACT

A modular downhole safety valve system comprising a plurality of valve modules being selectable in the field, the valve modules being connectable to one another in the field to define a modular safety valve having desired parameters and is ready for downhole deployment without additional certification.

BACKGROUND

In the resource recovery industry downhole safety valves are employed toprevent unwanted flow through a string. Due to the operationalimportance of such valves they must be certified in an API 14A facilitybefore they are approved for use in the field. The number of API 14Afacilities and their locations can cause delays in acquiring thecertification. As such, the industry is receptive to ideas that canlessen these delays.

SUMMARY

Disclosed is an embodiment of a modular downhole safety valve systemcomprising a plurality of valve modules being selectable in the field,the valve modules being connectable to one another in the field todefine a modular safety valve having desired parameters and is ready fordownhole deployment without additional certification.

Disclosed is an embodiment of a plurality of valve modules for a modulardownhole safety valve ready for downhole deployment comprising at leasta first valve module and a second valve module both being selected fromthe plurality of valve modules such that assembly of the first valvemodule to the second valve module defines the modular downhole safetyvalve having selected parameters and being ready for downhole deploymentwithout additional certification.

Disclosed is an embodiment of a method of setting parameters of adownhole safety valve in the field comprising configuring a plurality ofvalve modules, each of the valve modules being connectable to others ofthe valve modules such that assembly of a first of the valve modules toa second of the valve modules defines the downhole safety valve havingselected parameters and being ready for downhole deployment withoutadditional certification; and providing the plurality of the valvemodules for selection in the field.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way.With reference to the accompanying drawings, like elements are numberedalike:

FIG. 1A-IC depict embodiments of a downhole safety valve systemdisclosed herein; and

FIG. 2 depicts an embodiment of a downhole safety valve disclosedherein.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosedapparatus and method are presented herein by way of exemplification andnot limitation with reference to the Figures.

Parameters for downhole safety valves, such as biasing forces thatdetermine setting loads, and control mechanisms for valve operation areoften selected by well operators for each specific application. Oncethese parameters are established the valves are constructed then sent toan API 14A facility for certification before being delivered to the wellwhere they are ultimately deployed. Embodiments disclosed herein providean alternate approach to this procedure. The embodiments allow finalassembly of downhole safety valves in the field that meet certificationwithout requiring the valves to be tested and certified after theirfinal assembly.

Referring to FIGS. 1A-1C, a downhole safety valve system disclosedherein is identified by reference character 10. The valve system 10includes a plurality of valve modules 16 connected together end-to-endin a daisy-chain fashion to define a complete downhole safety valve 18.Each of the valve modules 10 is tested and certified in an API 14Afacility prior to being delivered to the field. As such, no furthercertification testing is required when the separate valve modules 10 areassembled together in the field to form the completed valve 18. Thisalleviates bottlenecks and costs associated with shipping completedvalves to and from certification facilities, as well as time lost whilewaiting for shipping and testing to be done.

These pre-certified valve modules 16 can be provided to the field andstored there near to where they will ultimately be deployed. Then whenan operator needs a new safety valve 18 and has established theparameters for it, he can simply select the specific valve modules 16that together will define the downhole safety valve 18 desired, retrievethem from storage, assemble them together, and proceed with welloperations.

The downhole safety valve 18A in FIG. 1A, consists of three of the valvemodules 16. One is a flapper module 16A, the second is a spring module16B, and the third is a control module 16C. This valve 18A may beconfigured to operate at a depth of 500 to 1500 feet, for example basedon a biasing force of the spring module 16B.

The safety valve 18B of FIG. 1B is configured to operate at a depth of2,000 to 3,000 feet. It differs from the valve 18A in that it has anadditional spring module 16D. A spring force of the spring module 16D isadditive to the spring force of the spring module 16B thereby accountingfor the difference in operating depth. This modularity allows for anypractical number of the spring modules to be added. For example, thesafety valve 18C shown in FIG. 1C has a third spring module 16E added tothe spring modules 16B and 16D, thereby increasing the operational depthof the valve 18C to a range of 3,500 to 4,500 feet.

The valve modules 16A-16D all use a common connection scheme so thatthey are interchangeable. For example, in one embodiment, the valvemodules 16A-16D each had a male thread 22 on one end and a female thread26 on the opposing end. This allows any of the valve modules 16A-16D toconnect to any other of the valve modules 161-16D.

The safety valve 18D of FIG. 2 has five valve modules; a bottom submodule 16F, a flapper module 16G, a spring module 16H, a control module16J, and a nipple adapter module 16K. The nipple adapter module 16K andbottom sub module 16F configure the safety valve 18D to be easilyincorporated into a larger production string. The various valve modules16A-16J can alter various functional parameters of the safety valve 18D.For example, the valve modules 16A-16J can determine a closure mechanismand/or an operating mechanism of the downhole safety valve 18. This candetermine whether the valve 18 has an equalizing or a non-equalizingoption. Similarly, this can determine whether the valve operatingmechanism includes a standard or a deep-set variant.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1

A modular downhole safety valve system comprising a plurality of valvemodules being selectable in the field, the valve modules beingconnectable to one another in the field to define a modular safety valvehaving desired parameters and is ready for downhole deployment withoutadditional certification.

Embodiment 2

The modular safety valve system of any prior embodiment, wherein morethan one of a same type of the valve modules can be employed to definethe desired parameters.

Embodiment 3

The modular safety valve system of any prior embodiment, wherein thevalve modules are spring modules, and biasing forces of the more thanone spring modules are additive.

Embodiment 4

The modular safety valve system of any prior embodiment, wherein each ofthe modules includes a first threaded end and a second threaded end, thefirst threaded end and the second threaded end of one of the valvemodules being configured to threadably engage with threaded ends ofother of the valve modules in a daisy-chain fashion.

Embodiment 5

The modular safety valve system of any prior embodiment, wherein thevalve modules are selectable from the group comprising: a nipple adaptermodule, a control module, a spring module, a flapper module, and abottom sub module.

Embodiment 6

The modular safety valve system of any prior embodiment, wherein thedesired parameters including at least one of a valve closure mechanismand a valve operating mechanism.

Embodiment 7

The modular safety valve system of any prior embodiment, wherein thevalve closure mechanism includes at least one of an equalizing mechanismand a non-equalizing mechanism.

Embodiment 8

The modular safety valve system of any prior embodiment, wherein thevalve operating mechanism includes at least one of a standard and adeep-set variant.

Embodiment 9

A plurality of valve modules for a modular downhole safety valve readyfor downhole deployment comprising at least a first valve module and asecond valve module both being selected from the plurality of valvemodules such that assembly of the first valve module to the second valvemodule defines the modular downhole safety valve having selectedparameters and being ready for downhole deployment without additionalcertification.

Embodiment 10

The valve module of any prior embodiment, wherein the first valve moduleand the second valve module each include a first threaded end and asecond threaded end, the first threaded end and the second threaded endbeing configured to threadably engage with threaded ends of other modulein a daisy-chain fashion.

Embodiment 11

The valve module of any prior embodiment, wherein the first valve moduleis a first spring module configured to be connected in the field to thesecond valve module that is a second spring module to define a totalvalve biasing force.

Embodiment 12

The valve module of any prior embodiment, wherein at least one of thefirst valve module and the second valve module determines whether avalve closure mechanism is an equalizing mechanism and a non-equalizingmechanism.

Embodiment 13

The valve module of any prior embodiment, wherein at least one of thefirst valve module and the second valve module determines whether thevalve operating mechanism is a standard or a deep-set variant.

Embodiment 14

The valve module of any prior embodiment, wherein at least one of thefirst valve module and the second valve module determine a valve closuremechanism and a valve operating mechanism of the modular downhole safetyvalve.

Embodiment 15

A method of setting parameters of a downhole safety valve in the fieldcomprising configuring a plurality of valve modules, each of the valvemodules being connectable to others of the valve modules such thatassembly of a first of the valve modules to a second of the valvemodules defines the downhole safety valve having selected parameters andbeing ready for downhole deployment without additional certification;and providing the plurality of the valve modules for selection in thefield.

Embodiment 16

The method of setting parameters of a safety valve of any priorembodiment, further comprising certifying each of the plurality of valvemodules in an API 14A facility.

Embodiment 17

The method of setting parameters of a safety valve of any priorembodiment, further comprising configuring the plurality of valvemodules to be connectable to others of the valve modules in anend-to-end daisy-chain fashion.

Embodiment 18

The method of setting parameters of a safety valve of any priorembodiment, further comprising configuring the plurality of valvemodules to be connectable to others of the valve modules such that anoperating parameter of the safety valve is determined by a number of asame type of the valve modules assembled.

Embodiment 19

The method of setting parameters of a safety valve of any priorembodiment, further comprising configuring the plurality of valvemodules to be connectable to others of the valve modules such that atleast one of a valve closure mechanism and a valve operating mechanismof the downhole safety valve is defined by which of the valve modulesare assembled in the field.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. Further, it should be noted that the terms “first,” “second,”and the like herein do not denote any order, quantity, or importance,but rather are used to distinguish one element from another. Themodifier “about” used in connection with a quantity is inclusive of thestated value and has the meaning dictated by the context (e.g., itincludes the degree of error associated with measurement of theparticular quantity).

The teachings of the present disclosure may be used in a variety of welloperations. These operations may involve using one or more treatmentagents to treat a formation, the fluids resident in a formation, awellbore, and/or equipment in the wellbore, such as production tubing.The treatment agents may be in the form of liquids, gases, solids,semi-solids, and mixtures thereof. Illustrative treatment agentsinclude, but are not limited to, fracturing fluids, acids, steam, water,brine, anti-corrosion agents, cement, permeability modifiers, drillingmuds, emulsifiers, demulsifiers, tracers, flow improvers etc.Illustrative well operations include, but are not limited to, hydraulicfracturing, stimulation, tracer injection, cleaning, acidizing, steaminjection, water flooding, cementing, etc.

While the invention has been described with reference to an exemplaryembodiment or embodiments, it will be understood by those skilled in theart that various changes may be made and equivalents may be substitutedfor elements thereof without departing from the scope of the invention.In addition, many modifications may be made to adapt a particularsituation or material to the teachings of the invention withoutdeparting from the essential scope thereof. Therefore, it is intendedthat the invention not be limited to the particular embodiment disclosedas the best mode contemplated for carrying out this invention, but thatthe invention will include all embodiments falling within the scope ofthe claims. Also, in the drawings and the description, there have beendisclosed exemplary embodiments of the invention and, although specificterms may have been employed, they are unless otherwise stated used in ageneric and descriptive sense only and not for purposes of limitation,the scope of the invention therefore not being so limited.

What is claimed is:
 1. A modular downhole safety valve system comprisinga plurality of valve modules being selectable in the field, the valvemodules being connectable to one another in the field to define amodular safety valve having desired parameters and is ready for downholedeployment without additional certification.
 2. The modular safety valvesystem of claim 1, wherein more than one of a same type of the valvemodules can be employed to define the desired parameters.
 3. The modularsafety valve system of claim 2, wherein the valve modules are springmodules, and biasing forces of the more than one spring modules areadditive.
 4. The modular safety valve system of claim 1, wherein each ofthe modules includes a first threaded end and a second threaded end, thefirst threaded end and the second threaded end of one of the valvemodules being configured to threadably engage with threaded ends ofother of the valve modules in a daisy-chain fashion.
 5. The modularsafety valve system of claim 1, wherein the valve modules are selectablefrom the group comprising: a nipple adapter module, a control module, aspring module, a flapper module, and a bottom sub module.
 6. The modularsafety valve system of claim 1, wherein the desired parameters includingat least one of a valve closure mechanism and a valve operatingmechanism.
 7. The modular safety valve system of claim 6, wherein thevalve closure mechanism includes at least one of an equalizing mechanismand a non-equalizing mechanism.
 8. The modular safety valve system ofclaim 6, wherein the valve operating mechanism includes at least one ofa standard and a deep-set variant.
 9. A plurality of valve modules for amodular downhole safety valve ready for downhole deployment comprisingat least a first valve module and a second valve module both beingselected from the plurality of valve modules such that assembly of thefirst valve module to the second valve module defines the modulardownhole safety valve having selected parameters and being ready fordownhole deployment without additional certification.
 10. The valvemodule of claim 9 wherein the first valve module and the second valvemodule each include a first threaded end and a second threaded end, thefirst threaded end and the second threaded end being configured tothreadably engage with threaded ends of other module in a daisy-chainfashion.
 11. The valve module of claim 9 wherein the first valve moduleis a first spring module configured to be connected in the field to thesecond valve module that is a second spring module to define a totalvalve biasing force.
 12. The valve module of claim 9 wherein at leastone of the first valve module and the second valve module determineswhether a valve closure mechanism is an equalizing mechanism and anon-equalizing mechanism.
 13. The valve module of claim 9 wherein atleast one of the first valve module and the second valve moduledetermines whether the valve operating mechanism is a standard or adeep-set variant.
 14. The valve module of claim 9 wherein at least oneof the first valve module and the second valve module determine a valveclosure mechanism and a valve operating mechanism of the modulardownhole safety valve.
 15. A method of setting parameters of a downholesafety valve in the field comprising: configuring a plurality of valvemodules, each of the valve modules being connectable to others of thevalve modules such that assembly of a first of the valve modules to asecond of the valve modules defines the downhole safety valve havingselected parameters and being ready for downhole deployment withoutadditional certification; and providing the plurality of the valvemodules for selection in the field.
 16. The method of setting parametersof a safety valve of claim 15, further comprising certifying each of theplurality of valve modules in an API 14A facility.
 17. The method ofsetting parameters of a safety valve of claim 15, further comprisingconfiguring the plurality of valve modules to be connectable to othersof the valve modules in an end-to-end daisy-chain fashion.
 18. Themethod of setting parameters of a safety valve of claim 15, furthercomprising configuring the plurality of valve modules to be connectableto others of the valve modules such that an operating parameter of thesafety valve is determined by a number of a same type of the valvemodules assembled.
 19. The method of setting parameters of a safetyvalve of claim 15, further comprising configuring the plurality of valvemodules to be connectable to others of the valve modules such that atleast one of a valve closure mechanism and a valve operating mechanismof the downhole safety valve is defined by which of the valve modulesare assembled in the field.